Pile fabric



April28,1959` DKARPOF'F f 2,884,020

PILE FABRC Filed oct. 2s, 1957 2 sheets-snei 2 v l "www FIG. 3

United States Patent O PILE FABRIC David Karpoif, Amsterdam, N.Y., assignor to Mohasco Industries, Inc., Amsterdam, N.Y., a corporation of New York Application October 23, 1957, Serial No. 691,934

3 Claims. (Cl. 139-403) This invention relates to pile fabrics of the type used as floor coverings and comprising a backing of stuier warps and weft shots in upper and lower series bound against the stuffer warps by chain warps and a pile made of pile warps having portions bound in the backing and other portions rising from the Ibacking as pile elements. More particularly, the invention is concerned with a pile fabric of the type referred to, in which the pile is made up of a novel combination of single and float loops and tuft legs resulting from the cutting of loops. The loops Iand tuft legs are aligned transversely of the fabric and may vary in height, so that attractive and unusual surface effects in the pile are obtained. In addition to the fabric, the invention includes a method by which the fabric may be produced rapidly and eciently.

In the weaving of the new fabric Iby the method, a pile wire loom is yemployed and a set of wi-res is provided, in which the odd wires are cutting wires and the even wires are non-cutting and wavy, that is, of varying height from end to end. The wavy wires are of such form and arrangement that the high spots on each wire are out of registry with such spots on the |adjacent wires and, preferably, the cutting wires are of a height not substantially greater than that of the low spots on the wavy wires. The pile yarns are arranged in two groups with the yarns of the groups intermingled and, ordinarily, the yarns of the two groups alternate across the fabric. The pile yarns of the two groups are diiferently manipulated in the weaving operati-on and the yarns of one group are bound beneath successive independent pairs of weft shots along the fabric and rise between adjacent independent pairs of adjacent weft shots to form single pile loops lying in transverse rows and varying in height along the rows. The pile yarns of the second group are bound beneath alternate `weft shots and rise to pass over the intermediate weft shots, so that, during the weaving and before the pile wires have been withdrawn, yeach yarn of the second group lies above both cutting and noncutting wires. As the wires beneath a raised portion of a yarn of the second group are withdrawn, the cutting wire may cut the yarn or leave it uncut depending upon the height of the wavy wire, over which the yarn passes. The yarns of the second group thus form both float loops and tuft legs in the same transverse row and the oat loops vary in height along the rows.

For a better understanding of the invention, reference may be made to the |accompanying drawings, in which:

Fig. 1 is a diagrammatic exploded perspective view of the new fabric with a pair of pile wires in place at one end;

Fig. 2 is a view in elevation of four pairs of wires forming part of the set of wires used in weaving the fabric;

Fig. 3 is a diagrammatic longitudinal sectional view showing a pile yarn of one group raised over the wires shown in Fig. 2 along the line 3-3 in that figure; and

Fig. 4 is a view similar to Fig. 3, showing a pile yarn Mice of the second group raised over the wires shown in Fig. 2 along the line 4-4 in that ligure.

The fabric of the invention in the form shown in the drawings includes a backing 10 made up of stuifer warps 11, weft shots 12, 13 in upper and lower series, respectively, above and below the stutter warps, and binder or chain warps 14, 15 in two sets binding vthe weft shots against the stuffer warps. The binder chains are arranged in pairs in the fabric with each pair made up of a chain of each set and the stuifer warps lie in groups between adjacent pairs of binder chains. In the fabric illustrated, there are four stuter warps in each group but the number may vary, as desired.

The pile yarns are arranged in two groups, which are intermingled and, ordinarily, the yarns of the two groups alternate across the fabric. The pile yarns of one group are typified by the yarn 16 and these yarns are 'bound beneath alternate weft shots 12 of the upper series and pass over the intermediate weft shots. Thus, in Fig. 3, the yarn 16 is bound beneath the odd weft shots of the upper series counting from the left, and pass over the even weft shots. The pile yarns of the second group are typied by the yarn 17 and these yarns are bound beneath successive independent pairs of adjacent weft shots of the upper series and rise to form loops between adjacent independent pairs of adjacent weft shots. Accordingly, in Fig. 4, the yarn 17 is bound beneath the first two upper weft shots, the third and fourth upper weft shots, the fth and sixth upper weft shots, etc., and rises between the adjacent independent pairs, that is, between the pair made up of rst and second shots and the pair made up of the third and fourth shots, etc.

The fabric is woven on a pile wire loom and the set of wires used includes cutting wires and wavy non-cutting wires. The wavy wires used are similar in shape, but are so formed that, in the set of wires, the high spots on each wavy wire lie out of registry with the high spots on the adjacent wavy wires. In forming the set for use in a loom, the cutting and wavy wires are arranged in alternation, so that the od-d wires in the set are cutting wires and the even wires are wavy wires, or vice versa. The cutting wires have a height approximately equal to the height of the low spots on the wavy wires.

Typical wires for use in the production of the new fabric are shown in Fig. 2, -in which the wires 18, 19, 20, and 21 are cutting wires of uniform height throughout the portion of their length, which is to lie within the shed. At the ends of the wires which trail during withdrawal of the wires from the fabric, the wires cartal knives of conventional construction marked 18a, 19a, 20a, 21a, respectively. The wavy wires 22, 23, 24, 25 are similar in the length and shape of their high spots and of the low sections connecting the high spots, but dilfer in the disposition of the high spots along the length of the wires. The four wires 22,-25, incl., constitute a sub-set -and the wavy wires next following the wire 25 in the main set is of the same construction as the wire 22. The low spots, such as the spot 22a on wire 22, are of the same height as the cutting wires 18, while the high spots, such as the spot 22h, are substantially higher. Each high spot has a sloping surface, such as the surface 22e, which lies at the leading end of the high spot, when the wire is being withdrawn, while the trailing end of each high spot is vertical.

The method of weaving the new fabric involves carrying out repeated weaving cycles, in each of which is formed a first shed, 4in which the pile yarns 16 are in the upper line, the chain warps 1S are in the lower line, and the remaining warp yarns lie in an intermediate substantially horizontal position. A cutting wire is then inserted in the upper part of the shed and a lower weftv shot 13 is simultaneously inserted into the lower part of the shed. The wire and weft shot are beaten up and a second shed is formed, in which the chain warps 14 and the pile yarns 16 are in the upper line, and all the remaining warp yarns are in the lower line. An upper weft shot 12 is inserted in the second shed and beaten up to complete the cycle. When the first shed o-f the second cycle is formed, the Warp yarns 16, 17 of both groups lie in the upper line, the chain warps 14 are in the lower line, and all the remaining yarns extend substantially horizontal. The wire inserted into the upper part of this shed is a wavy wire and pile yarns 16, 17 pass over both low and high spots thereon.

The remaining odd weaving `cycles are like the first in that, in the first shed of each cycle, in which a cutting wire is to be inserted, the pile yarns 16 are raised while the pile yarns 17 remain substantially horizontal. The remaining even cycles are like the second in that, in the first shed, into which a wavy wire is to be inserted, the pile yarns 16, 17 of both groups are raised to pass over the wire.

When all the wires in the set have been inserted, the first cutting wire 18 is withdrawn and inserted in the first shed in the next cycle. 1n the withdrawal of the wire, its knife passes freely beneath pile yarns 16, which are raised over high `spots of the following wavy wire 22, but cuts yarns 16, which pass over spots on the wavy wire, which are lower than the upper end of the knife. As a result, the withdrawal of a cutting wire severs certain of the yarns 16 to form tuft legs, `but does not cut the remaining yarns 16.

Withdrawal of the wavy wire 22 leaves pile loops of yarns 16, which have not been severed by the withdrawal of the knife wire 18 and other loops formed of yarns 17. In the withdrawal of the wire 22, the high spots on the wire must pass through all the loops of yarn raised over the wire and, as a result, the loops of yarns 17 raised over low spots 22a on the wire are increased to the height of the high spots. The yarn required to increase the height of the low loops to convert them to high loops is obtained by robbing loops in the preceding row in the fabric, and, as a result, the loops of yarn 17 in the finished fabric vary in length along a row raised over a wire and the height of these loops corresponds to the height of the parts of the following wavy wire, over which the yarns making up the loops are raised. The withdrawal of the wavy wire has little effect on loops of yarn 16, since those loops are made of yarns, which were raised over the high spots of the wavy wire or over high portions of the sloping surfaces thereon.

The fabric shown in Fig. 1 was produced in twelve Weaving cycles, in which the wires shown in Fig. 2 were employed. The pile elements in the fabric are of -the kind and form produced by withdrawal of a complete sub-set of wires as shown in Fig. 2 plus the wires 18, 22 of the second sub-set. The wires shown within the fabric are the third and fourth wires 19, 23 of the second sub-set.

In the fabric of Fig. l, the pile elements in the first row comprise high loops 26, 27 of yarns 16, 17, respectively, with the loops 26 'bound beneath upper weft shots 28, 30 and passing over the intermediate weft shot 29. The yarns forming loops 27 are bound beneath upper weft shots 28, 29, raised between weft shots 29, 30, and bound lbeneath weft shots 30, 31. The loop 32 is made of a yarn 26 and it is lower `than loops 26, 27 because of having had yarn robbed therefrom in order to produce a loop of maximum height of the saine yarn in the following row. The loop 33 of yarn 17 has been similarly reduced in height by having had yarn robbed therefrom.

The tuft leg 34 is formed of a yarn 26, which was raised over the cutting wire 18 and over a low spot on the adjacent wavy wire 22. Upon withdrawal 0f the cutting wire, the loop of yarn was severed to form the short tuft leg 34 extending from the weft shot 28 to the top of the cutting wire and the longer tuft leg 35 formed of the yarn extending from the top of the wire 18 over the wire 22 to the weft shot 30. The tuft legs 36 were formed in the same way as tuft leg 35, but the loo-ps cut to form them were raised over lower spots on the wire 22, so that the legs 36 are shorter than the leg 35.

In the fabric illustrated, the shape of the wavy wires is such that each twenty-four pile yarns across the fabric form loops and tuft legs in au arrangement, which is repeated elsewhere throughout the pile. Thus, starting at the left in the first row of the fabric shown in Fig. 1, there are six high loops, two loops of successively lower height, and three pairs of loops each made up of a high loop and a loop of lowest height. Next, there are five tuft legs followed by respective loops, the first tuft leg being higher than the others, which are of uniform height, and the first two loops being of lowest height and the last three of maximum height. The same sequence of high and low loops and high and low tuft legs can be found in every row, although the sequences are out of phase because the wavy wires are out of registry.

ln the new fabric, the relative proportions of loops and tuft legs in the pile depend on the form and arrangement of the wavy wires and the height of the cutting wires used in the weaving operation and various effects can be obtained by proper selection of the wires. If more tufts are desired, for example, cutting wires with higher knives may be used or wavy wires with longer low spots may be employed. Other possible variations in the pile of the fabric will be apparent and, in all instances, the presence in the pile of the fioat and single loops and the tuft legs gives the fabric an interesting and attractive surface appearance.

I claim:

l. A pile fabric having stufer warps, weft shots in upper and lower series on opposite sides of the stuffer warps, chain warps binding the weft shots against the stuffer warps, and pile warps in two groups intermingled across the fabric, the pile warps of one group being bound beneath successive independent pairs of adjacent weft shots along the fabric and rising between adjacent independent pairs of adjacent weft shots to form pile loops lying -in transverse rows and varying in height along the rows, the pile warps of the second group being bound beneath alternate weft shots and rising to pass over intermediate weft shots to form pile elements lying in transverse rows and made up of pairs of tuft legs and loops Varying in height along the rows.

2. The pile fabric of claim 1, in which the pile warps are bound beneath weft shots in the upper series.

3. The pile fabric of claim l, in which the pile elements made of pile warps of the second group are bound at their trailing side under the leading weft shots of said independent pairs.

References Cited in the file of this patent UNITED STATES PATENTS 2,685,894 Parlin Aug. 10, 1954 2,708,457 Gebert May 17, 1955 2,708,458 Gebert May 17, 1955 2,729,246 Groat Jau. 3, 1956 2,800,147 Groat July 23, 1957 2,807,283 Ianney et al Sept. 24, 1957 

